Thermoplastic forming tool

ABSTRACT

A thermoplastic forming tool includes a wand that includes a handle, a tip, and a conduit coupling the handle to the tip. The tip includes a heating element, a forming shoe, and a forming shoe support. During use, heat from the heating element heats the forming shoe to a temperature at or above the glass transition temperature of a thermoplastic polymer. The thermoplastic forming tool may be used to apply a thermoplastic material to a surface.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The invention generally relates to thermoplastic forming tools that useheat to melt a thermoplastic material.

2. Description of the Relevant Art

Many types of vehicle bodies are formed from a plurality of panels thatare connected to an underlying frame to form the outer surface of thevehicle. The panels are typically connected to the underlying frameusing multiple bolts. To improve the aerodynamic surface of the vehicle,the bolts are typically countersunk so that the head of the bolt isbelow the surface of the panel.

To further improve the aerodynamic surface of a vehicle, a plug may beplaced into the countersunk hole to fill the hole up to the surface ofthe panel. In some embodiments, the countersunk hole is filled with athermoplastic material by softening or melting the material and shapingthe material to match the surface. A thermoplastic shaping tool can beused to shape the thermoplastic material to plug the countersunk hole.Such a tool typically includes a heated wand which has a tip that is ata temperature that is at or above the glass transition temperature, orthe melting point, of the thermoplastic material. Such devices sufferfrom numerous safety issues, particularly when the devices need to bemoved to different areas of a vehicle. It is therefore desirable toprovide a thermoplastic forming tool which is portable and safe to use.

SUMMARY OF THE INVENTION

In an embodiment, a thermoplastic forming tool comprises: a wand whichincludes a handle, a tip, and a conduit coupling the handle to the tip.The tip includes a heating element, a forming shoe, and a forming shoesupport. The forming shoe is removably connected to the forming shoesupport. During use heat from the heating element heats the forming shoeto a temperature at or above the glass transition temperature of athermoplastic polymer. The thermoplastic forming tool also includes acontroller. The controller includes a body. The body of the controllerincludes a first compartment and a second compartment. The firstcompartment includes a processor and the second compartment isconfigured to hold at least a portion of the wand during use. Theprocessor is operable to execute program instructions. The programinstructions are operable to: determine the temperature of the heatingelement; and adjust an electrical current provided from a power sourceto the heating element to adjust the temperature of the heating element.

The body of the controller includes a coupling element that allows thecontroller to be coupled to an article of clothing or a belt of a userof the thermoplastic forming tool.

In an embodiment, the forming shoe support comprises an alignmentfeature that has a shape and size that is complementary to an alignmentopening of the forming shoe, or the forming shoe support comprises analignment opening that has a shape and size that is complementary to analignment feature of the forming shoe. When the forming shoe isconnected to the forming shoe support, the alignment feature mates withthe alignment opening such that the rotation of the forming shoe aboutthe forming shoe support is inhibited.

In an embodiment, the conduit comprises one or more vent openings formedthrough the conduit.

In an embodiment, the forming shoe is a rounded block having a widthgreater than the conduit.

In an embodiment, the second compartment includes a tip support and awand retention bracket. During use, the tip of the wand is placed on thetip support and the conduit is placed on the wand retention bracket. Inan embodiment, the wand retention bracket includes a slot sized toreceive the conduit. During use the conduit resides in the slot when thetip is placed on the tip support. In an embodiment, the wand retentionbracket includes an elastic plate that forces the conduit against aretention wall. The first compartment may be sealed and the secondcompartment may be open. The second compartment may include one or morevent openings.

During use, the controller is set to a preset temperature. Thecontroller provides sufficient electrical current to the heating elementto heat the heating element to the preset temperature. In someembodiments, the preset temperature is a temperature of 400° F. orgreater. In an embodiment, the preset temperature is set by coupling thecontroller to a computer having software that allows a user to adjustthe preset temperature.

In an embodiment, a method of applying a thermoplastic material to asurface using a thermoplastic tool, as described herein, includes:heating the forming shoe to a temperature at or above the glasstransition temperature of the thermoplastic polymer; placing the formingshoe against the thermoplastic material to alter the shape of thethermoplastic material to fit into an opening on the surface; andplacing the heated tip of the wand into the body of the controller.

In another embodiment, a thermoplastic forming tool includes a wandcomprising a handle, a tip, and a conduit coupling the handle to thetip. The tip includes a heating element, a forming shoe, and a formingshoe support. The forming shoe may be removably connected to the formingshoe support. During use, heat from the heating element heats theforming shoe to a temperature at or above the glass transitiontemperature of a thermoplastic polymer. The thermoplastic forming toolalso includes a controller. The controller includes a body. The body ofthe controller includes a first compartment and a second compartment.The first compartment includes a processor. The second compartment isconfigured to hold at least a portion of the wand during use. The firstcompartment includes a thermostat coupled to the processor. Thethermostat measures the temperature inside the first compartment anddisconnects the supply of electrical current to the heating element whenthe temperature inside the first compartment is above a predeterminedcompartment high temperature. The processor is operable to executeprogram instructions. The program instructions are operable to:determine the temperature of the heating element; and adjust anelectrical current provided from a power source to the heating elementto adjust the temperature of the heating element. The thermostatmeasures the temperature inside the first compartment and disconnectsthe supply of electrical current to the heating element when thetemperature inside the first compartment is above a predeterminedcompartment high temperature.

In some embodiments, the thermostat is further operable to restart theelectrical current provided to the heating element when the temperatureinside the first compartment drops below a predetermined compartment lowtemperature. The thermostat is further operable to restart theelectrical current provided to the heating element when the wand is inthe second compartment and the temperature in the first compartment isbelow the predetermined compartment low temperature.

In an embodiment, a method of applying a thermoplastic material to asurface using a thermoplastic tool, as described herein, includes:heating the forming shoe to a temperature at or above the glasstransition temperature of the thermoplastic polymer; placing the formingshoe against the thermoplastic material to alter the shape of thethermoplastic material to fit into an opening on the surface. The methodfurther includes: placing the wand into the second compartment of thebody; monitoring the temperature of the second compartment; andadjusting the current supplied to the heating element based on thetemperature in the second compartment.

In another embodiment, a thermoplastic forming tool includes a wandincluding a handle, a tip, and a conduit coupling the handle to the tip.The tip includes a heating element, a forming shoe, and a forming shoesupport. The forming shoe being removably connected to the forming shoesupport. During use, heat from the heating element heats the formingshoe to a temperature at or above the glass transition temperature of athermoplastic polymer. The controller includes a processor that isoperable to execute program instructions. The program instructions areoperable to: determine the temperature of the heating element; andadjust an electrical current provided from the power source to theheating element to adjust the temperature of the heating element. Thethermoplastic forming tool further comprises a primary temperaturesensor coupled to the heating element and the controller; and asecondary temperature sensor coupled to the heating element and thecontroller. The controller is set to a preset temperature. Thecontroller provides sufficient electrical current to the heating elementto heat the heating element to a preset temperature. In someembodiments, the preset temperature is a temperature of 400° F. orgreater. The preset temperature may be set by coupling the controller toa computer having software that allows a user to adjust the presettemperature.

In an embodiment, the controller determines the temperature of theheating element with the primary temperature sensor and the secondarytemperature sensor. The controller discontinues the provided electricalcurrent if the temperature measured by the secondary temperature sensorexceeds a temperature limit that is greater than the preset temperature.

In an embodiment, a method of applying a thermoplastic material to asurface using a thermoplastic tool, as described herein, includes:heating the forming shoe to a temperature at or above the glasstransition temperature of the thermoplastic polymer. The method furtherincludes: measuring the temperature of the heating element with theprimary temperature sensor and the secondary temperature sensor;determining if the heating element is at or above the preset temperatureusing the primary temperature sensor; determining if the heating elementis above a preset temperature limit using the secondary temperaturesensor; discontinuing the electrical current to the heating element ifthe temperature measured by the secondary temperature sensor is at orexceeds the temperature limit. The temperature limit is greater than thepreset temperature.

In another embodiment, a thermoplastic forming tool includes a wand. Thewand includes a handle, a tip, and a conduit coupling the handle to thetip. The tip includes a heating element, a forming shoe, and a formingshoe support. The forming shoe is removably connected to the formingshoe support. The wand further includes a support coupled to the handle.During use, heat from the heating element heats the forming shoe to atemperature at or above the glass transition temperature of athermoplastic polymer. The controller includes a body and a processor,wherein the processor is operable to execute program instructions. Theprogram instructions are operable to: determine the temperature of theheating element; and adjust an electrical current provided from a powersource to the heating element to adjust the temperature of the heatingelement. The support inhibits the forming shoe from contacting a surfacewhen the thermoplastic forming tool is placed on the surface. In anembodiment, the support comprises a flange connected to the handle. Theflange has a sufficient size to inhibit the forming shoe from contactingthe surface. In an embodiment, the support comprises a substantiallyflat edge which is configured to rest against the surface. The flatedge, in contact with the surface, inhibits rotation of the tool whenresting against the surface.

In an embodiment, a method of applying a thermoplastic material to asurface using a thermoplastic tool, as described herein, includes:heating the forming shoe to a temperature at or above the glasstransition temperature of the thermoplastic polymer. The method furtherincludes placing the wand onto the surface such that the wand supportpositions the forming shoe away from the surface.

BRIEF DESCRIPTION OF THE DRAWINGS

Advantages of the present invention will become apparent to thoseskilled in the art with the benefit of the following detaileddescription of embodiments and upon reference to the accompanyingdrawings in which:

FIG. 1 depicts a general schematic diagram of a thermoplastic formingtool;

FIG. 2 depicts a front view of a thermoplastic forming tool;

FIG. 3A depicts a top view of a thermoplastic forming tool;

FIG. 3B depicts a back view of a thermoplastic forming tool;

FIG. 4A depicts a side view of a thermoplastic forming tool with thewand detached;

FIG. 4B depicts a side view of a thermoplastic forming tool with thewand attached;

FIG. 5 depicts a projection view of an embodiment of a wand;

FIG. 6 depicts a lateral cross-sectional view of a wand;

FIG. 7 depicts a vertical cross section view of a wand;

FIG. 8 depicts a close-up cross-sectional view of the tip;

FIG. 9 depicts an end of a wand with the forming shoe removed;

FIG. 10A depicts a projection view of a forming shoe;

FIG. 10B depicts a projection view of a forming shoe detached from awand;

FIG. 11 depicts an embodiment of heating element;

FIG. 12 depicts a bundled cable;

FIG. 13A depicts an interior view of the front piece of the controllerbody;

FIG. 13B depicts an exterior view of the front of the controller body;

FIG. 14A depicts an interior view of the back piece of the controllerbody;

FIG. 14B depicts an exterior view of the back piece of the controllerbody;

FIG. 15A depicts a top view of the assembled controller;

FIG. 15B depicts an electrical component layout of the interior of thecontroller body;

FIG. 16 depicts a schematic diagram of the electrical system for thethermoplastic forming tool;

FIG. 17A depicts a side view of the controller, showing the wandresiding in the second compartment; and

FIG. 17B depicts a cross sectional view of the second compartment with awand residing therein.

While the invention may be susceptible to various modifications andalternative forms, specific embodiments thereof are shown by way ofexample in the drawings and will herein be described in detail. Thedrawings may not be to scale. It should be understood, however, that thedrawings and detailed description thereto are not intended to limit theinvention to the particular form disclosed, but to the contrary, theintention is to cover all modifications, equivalents, and alternativesfalling within the spirit and scope of the present invention as definedby the appended claims.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

It is to be understood the present invention is not limited toparticular devices or methods, which may, of course, vary. It is also tobe understood that the terminology used herein is for the purpose ofdescribing particular embodiments only, and is not intended to belimiting. As used in this specification and the appended claims, thesingular forms “a”, “an”, and “the” include singular and pluralreferents unless the content clearly dictates otherwise. Furthermore,the word “may” is used throughout this application in a permissive sense(i.e., having the potential to, being able to), not in a mandatory sense(i.e., must). The term “include,” and derivations thereof, mean“including, but not limited to.” The term “coupled” means directly orindirectly connected.

The specific embodiments disclosed herein are included to demonstratepreferred embodiments of the invention. It should be appreciated bythose of skill in the art that the embodiments disclosed in the exampleswhich follow represent embodiments discovered by the inventor tofunction well in the practice of the invention, and thus can beconsidered to constitute preferred modes for its practice. However,those of skill in the art should, in light of the present disclosure,appreciate that many changes can be made in the specific embodimentswhich are disclosed and still obtain a like or similar result withoutdeparting from the spirit and scope of the invention.

FIG. 1 depicts a general schematic diagram of a thermoplastic formingtool 100. The tool 100 includes a controller 110 and a wand 120. Wand120 is coupled to controller 110 via a cable 115. Cable 115 transmits anelectric current to a heating element located in tip 130 of the wand,and returns the temperature sensor signals to controller 100. Theheating element is used to heat a forming shoe positioned in tip 130.The forming shoe is heated to a temperature sufficient to allow athermoplastic material to be at least partially softened when in contactwith the forming shoe. Softening or melting the thermoplastic materialallows the shape of the thermoplastic material to be altered. In mostcases, the forming shoe is heated to a temperature at or above the glasstransition temperature of the thermoplastic material. In someembodiments, the forming shoe is heated to a temperature at or above themelting point of the thermoplastic material.

Controller 110 is coupled to a power source (not shown) through powercable 140. Power cable 140 may be coupled to a wall outlet or a batterypower source. While power cable 140 is depicted as being external to thecontroller, if the power source is a battery power source, the cable andpower source may be placed inside controller 110. Alternatively, if thepower source is a battery power source, the battery may be a portableexternal battery that is carried by the user, along with thethermoplastic forming tool.

FIGS. 2-4 depict various views of an embodiment of a thermoplasticforming tool 200. These figures show a thermoplastic forming tool 200that is coupled to a stand 250. Stand 250 includes a wand clip 255 whichholds the wand when not in use. A coupling element 270 (e.g., a clip) isused to attach the controller body to the stand (See FIGS. 3A and 3B).The same coupling elements 270 may also be used to couple the controllerbody to an article of clothing or a belt of the user. A power button 260and a display 265 are mounted on the top surface of the thermoplasticforming tool. The display may provide the preset operating temperatureand/or the current temperature of the tip of the wand. Placing thedisplay and power buttons on the top surface offers an advantage for auser that is carrying the thermoplastic forming tool on their belt or ontheir clothing. During use, the user will only need to look down at thetool display 265 to view the information on the display.

For portable use, controller 210 of thermoplastic forming tool 200includes a body having a compartment to hold at least a portion of wand220. In this embodiment, the body of controller 210 includes a sidecompartment 280 which includes a space to receive at least tip 230 ofthe wand.

Side compartment 280 may have one or more openings 285 that pass throughthe side walls of the side compartment. Heat from the tip may pass outof the second compartment through the one or more openings.

FIG. 5 depicts a projection view of an embodiment of a wand. Wand 500may include three main parts. Handle 510, tip 530, and a conduit 520connecting the handle to the tip. Handle 510 is configured to be grippedby the user. Electrical cables (not shown) extend up through handle 510and conduit 520 to tip 530. The electrical cables include power cablesand temperature sensor cables. A support 515 is positioned on thehandle. Support 515 inhibits tip 530 from contacting a surface when thethermoplastic forming tool is placed on the surface. As depicted in FIG.5, support 515 may comprise a flange connected to the handle. Thesupport has a sufficient size to inhibit the tip from contacting asurface when the wand is placed on the surface. In one embodiment, thesupport comprises at least one substantially flat edge which isconfigured to rest against the surface. The flat edge, in contact withthe surface, inhibits rotation of the tool when resting against thesurface. Alternate supports are contemplated, including a retractablekick-stand support or a retractable V-support.

FIG. 6 depicts a lateral cross-sectional view of wand 500. Handle 510includes a groove, running longitudinally along the interior surface ofthe handle, to receive and secure conduit 520. In an embodiment, thelower portion of the conduit is disposed in the handle and the upperportion of the conduit extends between the handle and the tip. Cables(not shown) pass under conduit 520 through conduit 527 to tip 530. Asshown in this figure, support 515 is formed as an integral part of thehandle (e.g., a molded part of the handle). It should be understood,however, that a support may be formed from a separate material that isconnected to the handle.

FIG. 7 depicts a vertical cross section view of wand 500. Conduit 520extends from handle 510 (not shown on FIG. 7) and connects the handle totip 530. The conduit may include two sections. First section 525 is, inone embodiment, a tube that extends from tip to handle. First section525 comprises one or more vent openings 522 formed through the tube. Thevent openings help release heat from the conduit created when the tip isheated. Second section 527, in one embodiment, is a separate conduitconnected to the first section. Second section provides a conduit forthe electrical wires that provide power to the tip for heating. Thesecond section is isolated from the first section to reduce the amountof heat transferred to the wires.

FIG. 8 depicts a close-up cross-sectional view of the tip 530. Tip 530includes forming shoe 550 and heating element 540. Forming shoe 550 isconnected to heating element 540 using a screw (not shown) that passesinto a machined opening 552 in the forming shoe. A slot 524 in theconduit allows for adjustment of a screw that passes through the heatingelement into the forming shoe.

FIG. 9 depicts an end of the wand with the forming shoe removed. The endof the wand includes heating element 540 and forming shoe support 560.During use, forming shoe 550 is attached to forming shoe support 560.Heating element 540 heats the forming shoe when in use, the heat beingtransferred from the heating element to the forming shoe.

During use, heating element 540 is used to heat forming shoe 550 to atemperature at or above the glass transition temperature of athermoplastic polymer being used. In some embodiments, the heatingelement heats the forming shoe to a temperature at or above the meltingpoint of the thermoplastic polymer being used. After the forming shoereaches the desired temperature, the forming shoe is placed in contactwith the thermoplastic material. Through heat and pressure from theuser, the forming shoe is used to soften or melt the thermoplasticmaterial as needed. During use of the wand to alter the thermoplasticmaterial, substantial pressure is used by the user, which can cause theforming shoe to rotate about the end of the tip. To ensure that theforming shoe does not rotate about the end of the wand, an alignmentfeature and an alignment opening are used to inhibit rotation. Referringto FIG. 9, forming shoe support 560 includes an alignment feature (e.g.,a rectangular protrusion) 565. Forming shoe 550, depicted in FIG. 10A,includes an alignment opening (e.g., a slot) 555 which is complementaryin shape and size to the alignment feature on the forming shoe support.Referring to FIG. 10B, when forming shoe 550 is connected to formingshoe support 560, the alignment feature 565 mates with the alignmentopening 555 such that the rotation of the forming shoe about the formingshoe support is inhibited. While this particular embodiment includes aprotruding alignment feature on the forming shoe support, and acomplementary opening on the forming shoe, these can be reversed. Forexample, a protruding alignment feature may be formed on the formingshoe, and the alignment opening may be formed on the forming shoesupport.

Referring to FIG. 10A, the forming shoe is depicted as a rounded blockhaving sharp edges. It should be understood, however, that the formingshoe can have any shape suitable for the type of forming being done, andthe shape of the forming shoe is not limiting to the invention. Asdiscussed previously, forming shoe is connected to heating elementthrough a screw that passes through the heating element into the formingshoe. Forming shoe 550 includes a machined opening 552 having threadsthat are complementary to the screw being used to connect the formingshoe to the heating element. To attach forming shoe 550 to the tip ofthe heating wand a screw is passed through heating element 540. Anopening extending through the heating element is accessed through slot524 formed in the conduit. Once the screw is passed through the heatingelement, the end of the screw is aligned with opening 552 in formingshoe 550 and the screw advanced into the opening, pulling the formingshoe into contact with the heating element.

FIG. 11 depicts an embodiment of heating element 540. Heating element540 includes a heat plate 545 and cables 547 coupled to the heat plate.The heat plate may be formed from any material suitable for heating. Ina preferred embodiment, heat plate 545 is a ceramic heat plate (e.g., analuminum nitride heat plate). One or more temperature sensors may bedisposed within, or coupled to the heat plate. Cables may includemultiple wires bundled together within an outer insulating sleeve.Cables 547 include power supply wires and temperature sensing wires. Inone embodiment, three cables are attached to the heat plate: a powersupply cable, a first temperature sensor cable, and a second temperaturesensor cable. More or less cables may be present. The cables are passedthrough the conduit 520, specifically through second section 527 ofconduit 520. To protect the cables from the heat of the heat plate, thecables may be covered with an insulating sleeve 542. The insulatingsleeve may be formed from any suitable insulating material (e.g.,polytetrafluoroethylene).

The other component of the thermoplastic forming tool is the controller.The controller is composed of a body, a processor disposed in the bodyand a wand storage compartment. In one embodiment, the controller bodyis formed from two molded pieces (front and back) that are joinedtogether. FIG. 13A depicts an interior view of the front piece of thecontroller body. FIG. 13B depicts an exterior view of the front of thecontroller body. FIG. 14A depicts an interior view of the back piece ofthe controller body. FIG. 14B depicts an exterior view of the back pieceof the controller body.

FIG. 15A depicts a top view of the assembled controller. FIG. 15Bdepicts a schematic diagram of the interior of the controller body 600.Controller body 600 may be separated into two compartments. Firstcompartment 610 includes the electronic components for the thermoplasticforming tool. Second compartment 620 is used as a storage area for thewand. Referring to FIG. 15A, disposed on the top of the controller are apower button 612 and a display 614. The power button, in a preferredembodiment, will simply turn the thermoplastic forming tool on or off.The display 614 will provide information regarding the temperature ofthe tip of the wand. In one embodiment, as shown in FIG. 3, the displaymay provide the current temperature of the tip of the wand, and thepreset temperature of the tip of the wand. Other information concerningthe operating status of the thermoplastic forming tool may also bepresented on the display. In FIG. 15A, vent openings 622 can be seen onthe top face and side of second compartment 620. Heated air, produced byplacing a heated wand tip in the second compartment is released throughthe vent openings.

FIG. 15B shows the interior of the controller, divided into twocompartments. First compartment 610 includes an electronic controller630. The electronic controller is coupled to the external power sourcethrough the power cable. A power cable inlet 645 is formed in the body600. The power cable inlet 645 is, in some embodiments, a polymericcable support which inhibits the cable from being bent or twisted.Controller 630 is also coupled to the heating element through theheating element cables. Heating element cable inlet 640 may also includea polymeric cable support. In an embodiment, the external power cableand the heating element bundled cable is passed through the respectivepower cable inlets 645 and 640 and electrically coupled to controller630 and power switch 612. Display 614 is disposed on a top surface ofthe body, as shown in FIG. 3.

In an embodiment, all the cables from the heating element may be bundledinto a single cable to protect the cables. FIG. 12 depicts a bundledcable 700 that includes all the heating element cables: the heatingelement power cable 710, the primary temperature sensor cable 720, andthe secondary temperature sensor cable 730. These individual cables maybe embedded in insulation to form a bundled cable, as shown in FIG. 12.The insulation used to bundle the cables may be SJO rated insulation. Inan embodiment, the external power cable and the heating element bundledcable is passed through the respective power cable inlets (640 and 645)and electrically coupled to controller 630 and power switch 612.

FIG. 16 depicts a schematic diagram of the electrical system for thethermoplastic forming tool. Operation of the thermoplastic forming toolis controlled by an embedded microprocessor based PID temperaturecontroller which maintains a predetermined temperature (based on thepreset temperature). An exemplary temperature controller is the WatlowPM6C1CA-BLAJPWN controller. An external power supply (e.g., a facility230VAC) is electrically coupled to the temperature controller (C) andthe power switch (B). When the power switch is turned on, power flows tothe temperature controller and is passed on to the heating element (F).

Prior to use, the temperature controller is programmed to heat theheating element to a preset temperature. For use in deforming or meltingthermoplastic materials, the preset temperature is typically set at 400°F. or greater. The temperature controller includes a data port (G) whichcan be used to couple the temperature controller to a computer. In apreferred embodiment, the preset temperature can only be adjusted byconnecting the temperature controller to computer having software thatallows a user to adjust the preset temperature. This prevents the userfrom inadvertently altering the preset temperature while using thethermoplastic forming tool. In addition, controller 630 employsBluetooth communications allowing the controller to be programmedutilizing wireless technology.

After the device is powered on, the temperature controller determinesthe temperature of the heating element using the primary temperaturesensor (S1). If the temperature of the heating element is below thepreset temperature, the temperature controller sends a control signal torelay (E) which opens the switch sending power to the heating element(F). Using a feedback loop, the temperature controller continues tomonitor the temperature of the heating element, through the primarytemperature sensor, and provide electrical current to the heatingelement, until the heating element reaches the preset temperature. Oncethe preset temperature is reached, the electrical current isdiscontinued by sending a control signal to the relay to place theswitch in the off position. When the temperature of the heating elementdrops by a predetermined amount (e.g., 2° F., 4° F., 6° F., 8° F., 10°F., 15° F., 20° F., or 30° F.), the temperature controller willreinstate the electrical current to bring the heating element back tothe preset temperature.

The temperature controller also includes a HI-Limit control algorithm.The purpose of the HI-Limit control algorithm is to prevent the heatingelement from being heated over the preset temperature. After repeateduse, a condition may develop in the electrical circuitry that may causethe heating element to be heated without the temperature controllerknowing that there is a defect. For example, if the primary temperaturesensor is damaged, the temperature controller may not receive anaccurate temperature of the heating element. The temperature controllermay continue to send an electric current to the heating element in anattempt to raise the temperature of the heating element. This can leadto overheating of the heating element which can create a dangeroussituation for the user and the tool. To prevent this kind ofoverheating, a secondary temperature sensor (S2) is connected to theheating element. When the heating element is being heated to the presettemperature, the temperature controller monitors both the primarytemperature sensor and the secondary temperature sensor. In oneembodiment, if the temperature of the heating element, as measured bythe secondary temperature sensor, exceeds a preset temperature limit,the temperature controller discontinues the provided electrical current(e.g., by sending a control signal to the relay). The preset temperaturelimit is typically set at a temperature that is substantially greaterthan the preset temperature (e.g., 20° F., 30° F., 50° F., or 100° F.greater than the preset temperature).

In the event the temperature limit is exceeded, the temperaturecontroller will activate a fail-safe shutdown sequence which deactivates(turns off) the power to the heater. Once the Hi-Limit algorithm hasbeen activated, the device cannot be powered back on without humanintervention in order to reset the controller. Thus, the temperaturecontroller will not automatically resume normal control function, evenif the temperature decreases below the preset temperature limit. In anembodiment, the temperature controller may only be reset afterreplacement of the heating element and the associate temperaturesensors.

For portable use, the wand may be stored in second compartment 620 ofthe body of the controller. A side view of the controller, showing thewand residing in the second compartment, is shown in FIG. 17A. FIG. 17Bdepicts a cross sectional view of the second compartment with a wandresiding therein. In one embodiment, second compartment 620 isconfigured to hold at least a portion of the wand during use. As shownin FIG. 17A, the second compartment may include a tip support 700 and awand retention bracket 750. Tip support 700 includes a notched tray 710that is shaped to allow the tip of the wand to be lowered into the tray.Notched tray includes a planar platform having tabs 715 attached to theplatform. During use, the tip of the wand is passed into the top portionof the tip support and lowered into the notched tray. The tabs of thenotched tray help secure the wand in the tray.

The second compartment also includes a wand retention bracket 750.Referring to FIG. 17B, the wand retention bracket includes a slot 755sized to receive the conduit 520. The wand retention bracket may alsoinclude an elastic plate 760 which “locks” the wand into the wandretention bracket. In the present embodiment, during storage of the wandin the second compartment, the tip of the wand is placed into the tipsupport and the conduit is placed into the wand retention bracketthrough slot 755. As the conduit 520 moves into the wand retentionbracket, elastic plate 760 is deflected and provides a force against theconduit, forcing the conduit against retention wall 765. Retention wall765 includes a tab 770 which partially surrounds the conduit, securingthe conduit in the wand retention bracket.

To remove the wand from the second compartment, the wand is lifted abovethe tabs 715 of the notched tray. The conduit 520 is then pushed againstthe elastic plate 760 and pulled out of wand retention bracket 750through slot 755.

When the heated tip of the wand is placed in the second compartment, thetip will begin heating the second compartment. As discussed previously,vent holes are formed in the sidewalls and the top of the secondcompartment to allow heat to escape from the second compartment.Preferably, the tip of the wand will remain heated to the presettemperature to allow rapid use of the wand when removed from the secondcompartment. Keeping the tip of the heated wand at temperatures of 400°F. or higher may lead to inadvertent heating of the first compartmentand the electronic shoes disposed therein. To prevent the electronicshoes in the first compartment from being damaged, a temperature sensoris disposed inside the first compartment to monitor the interiortemperature of the first compartment. In one embodiment, a printedcircuit board (PCB) thermostat may be used to monitor the temperature ofthe electronic shoes in the first compartment. Referring to FIG. 16, aPCB thermostat (D) is placed in the control circuit between thetemperature controller and the relay. During normal operation, the PCBthermostat is in a closed position (i.e., is a “normally closed”thermostat), allowing the control signals from the temperaturecontroller to reach the relay. When the temperature inside the firstcompartment reaches a predetermined compartment high temperature (e.g.,150° F.) the thermostat changes to an open position, breaking thecontrol signal connection between the temperature controller and therelay. The thermostat will remain in the open position until thetemperature drops below the predetermined compartment low temperature,(typically between about 5-30° F. below the compartment hightemperature). When the thermostat drops below the predeterminedcompartment low temperature the thermostat reverts back to the closedposition. This allows the temperature of the first compartment to beregulated, inhibiting damage to the electronic shoes due to excessiveheating of the first compartment.

Further modifications and alternative embodiments of various aspects ofthe invention will be apparent to those skilled in the art in view ofthis description. Accordingly, this description is to be construed asillustrative only and is for the purpose of teaching those skilled inthe art the general manner of carrying out the invention. It is to beunderstood that the forms of the invention shown and described hereinare to be taken as examples of embodiments. Elements and materials maybe substituted for those illustrated and described herein, parts andprocesses may be reversed, and certain features of the invention may beutilized independently, all as would be apparent to one skilled in theart after having the benefit of this description of the invention.Changes may be made in the elements described herein without departingfrom the spirit and scope of the invention as described in the followingclaims.

1. A thermoplastic forming tool comprising: a wand comprising a handle,a tip, and a conduit coupling the handle to the tip, the tip comprisinga heating element, a forming shoe, and a forming shoe support, theforming shoe being removably connected to the forming shoe support,wherein during use, heat from the heating element heats the forming shoeto a temperature at or above the glass transition temperature of athermoplastic polymer; a controller comprising a body, wherein the bodyof the controller comprises a first compartment and a secondcompartment, wherein the first compartment comprises a processor, andwherein the second compartment is configured to hold at least a portionof the wand during use; wherein the processor is operable to executeprogram instructions, and wherein the program instructions are operableto: determine the temperature of the heating element; and adjust anelectrical current provided from a power source to the heating elementto adjust the temperature of the heating element.
 2. The tool of claim1, wherein the body of the controller comprises a coupling element thatallows the controller to be coupled to an article of clothing or a beltof a user of the thermoplastic forming tool.
 3. The tool of claim 1,wherein the forming shoe support comprises an alignment feature that hasa shape and size that is complementary to an alignment opening of theforming shoe, or wherein the forming shoe support comprises an alignmentopening that has a shape and size that is complementary to an alignmentfeature of the forming shoe, and wherein when the forming shoe isconnected to the forming shoe support, the alignment feature mates withthe alignment opening such that the rotation of the forming shoe aboutthe forming shoe support is inhibited.
 4. The tool of claim 1, whereinthe conduit comprises one or more vent openings formed through theconduit.
 5. The tool of claim 1, wherein the forming shoe is a roundedblock having a width greater than the conduit.
 6. The tool of claim 1,wherein the second compartment comprises a tip support and a wandretention bracket, wherein the tip of the wand is placed on the tipsupport and the conduit is placed on the wand retention bracket duringuse.
 7. The tool of claim 6, wherein the wand retention bracketcomprises a slot sized to receive the conduit, wherein, during use, theconduit resides in the slot when the tip is placed on the tip support.8. The tool of claim 7, wherein the wand retention bracket comprises anelastic plate that forces the conduit against a retention wall.
 9. Thetool of claim 1, wherein first compartment is sealed and the secondcompartment is open.
 10. The tool of claim 1, wherein the secondcompartment comprises one or more vent openings.
 11. The tool of claim1, wherein the controller is set to a preset temperature, and whereinthe controller provides sufficient electrical current to the heatingelement to heat the heating element to the preset temperature, whereinthe preset temperature is a temperature of 400° F. or greater.
 12. Thetool of claim 1, wherein the preset temperature is set by coupling thecontroller to a computer or handheld device having software that allowsa user to adjust the preset temperature.
 13. A method of applying athermoplastic material to a surface, the thermoplastic tool comprising:a wand comprising a handle, a tip, and a conduit coupling the handle tothe tip, the tip comprising a heating element, a forming shoe, and aforming shoe support, the forming shoe being removably connected to theforming shoe support; a controller comprising a body, wherein the bodyof the controller comprises a first compartment and a secondcompartment, wherein the first compartment comprises a processor, andwherein the second compartment is configured to hold at least a portionof the wand during use; the method comprising. heating the forming shoeto a temperature at or above the glass transition temperature of thethermoplastic polymer; placing the forming shoe against thethermoplastic material to alter the shape of the thermoplastic materialto fit into an opening on the surface; and placing the heated tip of thewand into the second compartment of the body.
 14. A thermoplasticforming tool comprising: a wand comprising a handle, a tip, and aconduit coupling the handle to the tip, the tip comprising a heatingelement, a forming shoe, and a forming shoe support, the forming shoebeing removably connected to the forming shoe support, wherein duringuse, heat from the heating element heats the forming shoe to atemperature at or above the glass transition temperature of athermoplastic polymer; a controller comprising a body, wherein the bodyof the controller comprises a first compartment and a secondcompartment, wherein the first compartment comprises a processor, andwherein the second compartment is configured to hold at least a portionof the wand during use, and wherein the first compartment comprises athermostat coupled to the processor; wherein the processor is operableto execute program instructions, and wherein the program instructionsare operable to: determine the temperature of the heating element; andadjust an electrical current provided from a power source to the heatingelement to adjust the temperature of the heating element; wherein thethermostat measures the temperature inside the first compartment anddisconnects the supply of electrical current to the heating element whenthe temperature inside the first compartment is above a predeterminedcompartment high temperature.
 15. The tool of claim 14, wherein thethermostat is further operable to restart the electrical currentprovided to the heating element when the temperature inside the firstcompartment drops below a predetermined compartment low temperature. 16.The tool of claim 15, wherein the thermostat is further operable torestart the electrical current provided to the heating element when thewand is in the second compartment and the temperature in the firstcompartment is below the predetermined compartment low temperature.17-44. (canceled)